Page 1 Wire Rope Hoists Operation & Service Manual Before installing hoist, fill in the information below. Refer to the Hoist and Motor data plates. Model No. _____________________________________ Serial No. _____________________________________ Purchase Date _____________________________________ Voltage _____________________________________ Rated Load _____________________________________ Follow all instructions and warnings for inspecting, maintaining and operating this product. The use of any hoist presents some risk of personal injury or property damage.
Page 2 YALE/SHAWBOX HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA As a Yale/Shawbox Hoist and Trolley user you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Page 3: Table Of Contents
Contents General information ......................................7 Information about safety messages ................................7 1.1.1 Explanation of signal words and symbols ..............7 1.1.2 Safety instructions ......................7 1.1.3 Section safety messages ..................... 7 1.1.4 Embedded safety messages ..................7 1.1.5 Safety alert symbols ..................... 8 1.1.6 Additional symbol ......................
Page 4 4.8.2 Double rail trolley ......................40 Electrical equipment ....................................... 41 4.9.1 Supply cables ......................41 4.9.2 Terminals ........................41 4.9.3 Protection of equipment ..................... 42 4.9.4 Emergency stop ......................42 4.9.5 Runway conductor disconnecting means ..............42 4.9.6 Disconnect switch ...................... 42 4.9.7 Protective conductor ....................
Page 5 Hoist motor brake (NM) 4HS..................................103 7.9.1 Checking the brake ....................103 7.9.2 Replacing the brake rotor ..................104 7.10 Replacing the pressure springs .................................. 106 7.11 Travel motor brake ......................................107 7.12 Geared limit switch ......................................108 7.12.1 System description for geared limit switch - version 1 ..........
Page 6 11.3.2 Cable cross sections and lengths of supply cable for pole-changing hoist motors ../..H.......................... 162 11.4 Tightening torques ......................................163 11.5 Lubricants ........................................165 11.6 Lubricants for travel drive .................................... 165 11.7 Circuit diagrams ......................................165 07.2020...
Page 7: General Information
General information General information You have purchased a Yale product. This product was constructed in accordance with the applicable European standards and regulations. Read carefully and observe this manual. Store the manual within easy reach at the place of operation. Information about safety messages 1.1.1 Explanation of signal words and symbols...
Page 8: Safety Alert Symbols
General information 1.1.5 Safety alert symbols Symbol Meaning General hazard Electric shock hazard Falling parts hazard Suspended load hazard Hand injury hazard 1.1.6 Additional symbol Symbol Meaning Important note Spare parts WARNING Safety hazard. Incorrect or defective spare parts may lead to damage, malfunctions or the complete failure of the machine.
Page 9: Crane Logbook
General information Crane logbook A completed crane logbook must be kept for each hoist. The results of the periodic inspections must be entered in the logbook. Transport and storage Transport The product is delivered on a special pallet. This enables it to be loaded and unloaded safely with a fork-lift truck.
Page 10: After-Sales Service
General information After-sales service You have purchased a high-quality product. Our after sales service will give you advice on its correct use. In order to maintain the safety and constant availability of the product, we recommend concluding a maintenance agreement. Seminars: Comprehensive understanding of material handling products is a prerequisite for the correct use of equipment.
Page 11: General Safety Notes
General safety notes General safety notes The products are constructed according to the state of the art and recognized safety rules. However, during use danger to the life and limb of the user or a third party can arise, or adverse effects can affect the product and other property. Use for intended purpose •...
Page 12: Inappropriate Use
General safety notes Inappropriate use • Use in areas with potentially explosive atmosphere. • Transporting molten metal. • Exceeding the maximum working load. • Transporting persons. • Pulling/towing or raising/lowering of a guided load. • Using the hoist in applications in which the working load changes with the position of the load, as the hoist is not equipped with a load display and additional warning device when it cuts off at overload.
Page 13: Organizational Safety Precautions
General safety notes Organizational safety precautions • The owner may only employ insured persons to operate a crane single-handedly (crane operator), install or perform maintenance on the product if they are capable both physically and mentally, – have been instructed in operating and maintaining the crane and have shown him proof of their competence and –...
Page 14: Working Above Floor Level
General safety notes Working above floor level Personnel must be protected from falling. Observe the national, state, and local regulations, and company policies when working above the floor level. Sound pressure level The sound pressure level was measured at a distance of 3 ft from the wire rope hoist. The mean sound pressure level is calculated for one operating cycle (50% with maximum permissible load, 50% without load).
Page 15: Safety-Conscious Operation
General safety notes 2.10 Safety-conscious operation YK/SK wire rope hoists are constructed according to the state of the art and equipped with an overload safety device in standard version. In spite of this, dangers may arise from inappropriate use or use for an unintended purpose. 1.
Page 16: Introduction
Introduction Introduction Wire rope hoists are intended for lifting freely movable loads. The modular concept of our series of wire rope hoists permits a multitude of variations on the basis of series components. The design is characterized by the rope drum and hoist motor being arranged in parallel. The hoist drive is a cylindrical rotor motor with a separately activated D.C.
Page 17: Incorporation
Introduction Incorporation Stationary hoist (hoist for incorporation) The hoist is connected to a fixed structure by means of bolt joints permitting it to be attached to a base, wall or ceiling. Mobile hoist The hoists can be mounted on 4 different types of travel carriage. 07.2020...
Page 18: Installation
Installation Installation WARNING Improper assembly can cause material damage or severe injuries. ➢ Ensure that the supporting structure is designed for the maximum hoist load. ➢ Ensure that a competent person carries out the assembly. ➢ Adhere to the national and local safety and accident prevention regulations, the occupational safety acts and environmental provisions.
Page 19: Attachment At Bottom
Installation 4.1.1 Attachment at bottom YKA/SKA YKB/SKB ø D = 0.67 in ø D = 0.83 in (1) 6 × Screw, M16-8.8 (1) 6 × Screw, M20-8.8 (2) 12 × SCHNORR® Safety Washer S16 (2) 12 × SCHNORR® Safety Washer S20 (3) 6 ×...
Page 20 Installation YKE/SKE (1PS) ø D = 1.02 in (1) 8 × Screw, M24-8.8 (2) 16 × SCHNORR® Safety Washer S24 (3) 8 × Nut, M24-8 07.2020...
Page 21: Attachment At Top
Installation 4.1.2 Attachment at top YKA/SKA YKB/SKB ø D = 0.67 in ø D = 0.83 in (1) 8 × Screw, M16-8.8 (1) 7(8) × Screw, M20-8.8 (2) 16 × SCHNORR® Safety Washer S16 (2) 14(16) × SCHNORR® Safety Washer S20 (3) 8 ×...
Page 22: Fleet Angle
Installation Fleet angle 4.2.1 Attachment at bottom Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKC/ YKA/ YKB/ YKE/ α1 4° 5° 8° 8° α2 23° 13° 20° 18° α3 27° 30° 30° 30° α4 74° 73°...
Page 23: Attachment At Top
Installation 4.2.2 Attachment at top Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKE/ YKA/ YKB/ YKC/ α1 4° 5° 8° α2 23° 13° 20° α3 27° 30° 30° α4 74° 73° 76° α5 16° 17° 14°...
Page 24: Attachment At Side
Installation 4.2.3 Attachment at side Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKA/ YKB/ YKC/ YKE/ α1 21° 23° 18° α2 12° 13° 20° α3 74° 73° 76° α4 10° 10° 20° α5 21° 23° 18°...
Page 25: Angle Of Installation
Installation 4.2.5 Angle of installation WARNING Rope damage hazard. The wire rope must not touch the rope guide or structural elements. ➢ Always install the hoist horizontal. 1. Install hoists with rope drives with bottom hook blocks always horizontal to their longitudinal axis.
Page 26 Installation Nuts Nuts Trolley side cheek Support bolt Threaded bolt Fig. 12 Check flange width “B” and dimension “c” on the basis of Tab. 7 and adjust the trolley to the beam width if necessary. Adjustment work, dimension “c”: Loosen the nut (2). Adjust dimension “c”...
Page 27: Underslung Trolley Ue-S4
Installation 4.3.2 Underslung trolley UE-S4 Fig. 13 WARNING If the setting is established with the incorrect nuts (marked in the figure on the threaded rod end with an X), there is a risk of the load toppling. ➢ Only perform setting work with the nuts (1) and (2). 07.2020...
Page 28 Installation Preparatory work Threaded bolt Trolley side cheek Nuts Connection part Connecting pin Axle holder side Fig. 14 Check flange width “B” and dimension “c” on the basis of Tab. 9 and adjust the trolley to the beam width if necessary. –...
Page 29: Underslung Trolley Ue-S776
Installation Assembly with an inaccessible runway end Loosen the nuts (2) on the threaded bolts (3) and unscrew by dimension “x”. Slide the trolley side cheek (4) apart parallel, to the unscrewed nuts (2) until the dimension “B” + “y” is reached. Mount the trolley on the axle holder side (8) in the bottom flange of the runway beam and secure against slipping down.
Page 30 Installation Preparatory work Threaded bolt 2× trolley side cheek 2× nut Connection part Connecting pin Axle holder 2× nut (10) Panel Fig. 16 Check flange width “B” and dimension “c” on the basis of the table and adjust the trolley to the beam width if necessary. –...
Page 31: Articulated Trolley (Dke-S4 / Dke-S6)
Installation Assembly with an inaccessible runway end Loosen the nuts (2) on the threaded bolts (3) and unscrew by dimension “x”. Slide the trolley side cheeks (4) apart parallel, to the unscrewed nuts (2) until the dimension “B” + “y” is reached. Mount the trolley on the axle holder side (8) in the bottom flange of the runway beam and secure against slipping down.
Page 32 Installation Preparatory work Threaded rod Connecting pin Trolley side cheek Nut, M12 Lifting beam Fig. 18 Check flange width “B” and dimension “c” on the basis of the table and adjust the trolley to the beam width if necessary. – Observe here that the lifting beam (7) must be positioned centrally (to dimension “c”) between the trolley side cheeks (“e1”...
Page 33 Installation Assembly with an inaccessible runway end Loosen the nuts (2) on the threaded bolts (3) and unscrew by dimension “x”. Slide the trolley side cheeks (5) apart parallel, to the unscrewed nuts (2) until the dimension “B” + “y” is reached. Mount the trolley in the bottom flange of the runway beam and secure against slipping out.
Page 34: End Stops For Monorail Trolleys
Installation End stops for monorail trolleys WARNING Falling parts hazard. If there are no end stops, the trolley can travel over the end of the runway. ➢ Mount suitable end stops at the end of the runway before commissioning the hoist. The monorail trolleys are supplied as standard with buffers.
Page 35: Double Rail Trolley (Oe-S)
Installation Double rail trolley (OE-S) The double rail trolleys are supplied with mounted buffers. NOTICE The trolley must run smoothly over the whole runway without jamming or increased friction at the wheel flanges. Increased friction at the flanges due to poor beam quality or incorrect trolley adjustment may lead to increased wear.
Page 36: End Stops For Double Rail Trolleys
Installation End stops for double rail trolleys WARNING Falling parts hazard. If there are no end stops, the trolley can travel over the end of the runway. ➢ Mount suitable end stops at the end of the runway before commissioning the hoist. 4.6.1 Wheel diameter D = 3.9 in.
Page 37: Anti-Jump Catch (Option)
Installation Anti-jump catch (option) 4.7.1 Description of system The anti-jump catch acts as an anti-derail device, preventing the trolley jumping off the rail and falling. Trolley types OE-S04, OE-S05 Trolley types OE-S06, OE-S07 Fig. 24 Fig. 25 4.7.2 Procedure WARNING Falling parts hazard.
Page 38 Installation Vertical adjustment Measure dimension X, see Fig. Fig. 28 Select positions of hook and eccentric from the table. Trolley type OE-S04 Trolley type OE-S04 Trolley type OE-S05 Hook Eccentric Hook Eccentric Hook position Eccentric position position position [in] [in] 1.65...1.77 1.57...1.69 1.79...1.89...
Page 39 Installation Trolley types OE-S06 - OE-S07 Trolley types OE-S06 - OE-S07 Hook Eccentric Hook position Eccentric position position [in] 1.5...1.59 1.61...1.79 1.81...1.99 2.01...2.19 2.2...2.38 2.4...2.58 2.6...2.78 Fig. 31 2.8...2.97 2.99...3.17 3.19...3.37 3.39...3.56 3.58...3.76 • Unscrew fixing elements (1 + 2) •...
Page 40: Travel Limit Switches
Installation Travel limit switches 4.8.1 Monorail trolley The travel limit switches (optional) are mounted on the trolley. 4.8.2 Double rail trolley The travel limit switch assembly is supplied ready-wired but not mounted and must be secured to the towing arm for the power supply. WARNING Falling parts hazard.
Page 41: Electrical Equipment
Installation Electrical equipment DANGER Electric shock hazard ➢ Make sure an electrical qualified person performs the work. ➢ Observe the relevant safety and accident prevention regulations. Electrical equipment was installed per NFPA 70 or other National, State, and Local regulations. It comprises all electrical equipment of the hoist: •...
Page 42: Protection Of Equipment
Installation 4.9.3 Protection of equipment Protective devices include: • Devices for overcurrent protection (fuses, circuit breakers) • Motor protection devices • Overload safety devices • Temperature monitors • Limit switches The protective devices in the electrical equipment installed in the scope of supply must in no case be removed, replaced by different devices or bridged.
Page 43: Connection Fuses
Installation 4.9.8 Connection fuses • Overcurrent protection devices. • The fuse values must be observed so that the crane switch contacts do not weld if there is a short circuit and overload protection of lead is ensured. 4.9.9 Electromagnetic compatibility Electromagnetic compatibility (EMC) mainly concerns the emission of electromagnetic interference and the immunity of electronic components and systems to this interference.
Page 44: Overload Safety Device
Installation 4.9.10 Overload safety device The wire rope hoist is supplied with an overload protection. Description of system The overload safety device is a device which automatically prevents the hoist moving loads exceeding its safe working load during normal operation, taking into account the dynamic effects.
Page 45: Connecting To Mains
Installation Overload safety device by others When an overload safety device and thus the placement of the load sensors to measure the rope forces are designed by others, all requirements relating to rope reeving, fleet angle and angle of installation of the hoist must be observed, see section. 4.2 The overload safety device must be set during commissioning, see supplementary operating instructions.
Page 46: Control And Control Functions
Installation 4.9.12 Control and control functions Each hoist control is equipped with an electronic control device. This electronic control device functions as a central safety device for the overload safety device and as motor control and monitoring unit. The device functions are adapted to the different hoist and drive types and the particular function modules selected (load limits, pole-changing or frequency-controlled motors, etc.) by parameterizing the device.
Page 47: Electric Motors And Related Equipment
Installation 4.9.13 Electric motors and related equipment The hoist motors meet the standards of EN 60034-1 and are specially dimensioned and designed for hoist operating conditions. Hoist motor • 12/2-pole motor with separately controlled D.C. brake for contactor control – The brake is designed as an operating brake •...
Page 48: Hook Operated Hoist Limit Switch With Weight Ball "Bls" (Option)
Installation 4.11 Hook operated hoist limit switch with weight ball “BLS” (option) The hook operated hoist limit switch is also available as “hook operated hoist limit switch with switch rod” variant. Only one variant can be mounted. min. distance to first obstacle Dimension between emergency and operational hoist limit switching, “top”...
Page 49: Adjusting/Mounting Hook Operated Hoist Limit Switch With Weight Ball
Installation 4.11.1 Adjusting/mounting hook operated hoist limit switch with weight ball Adjust the geared limit switch, see Adjusting the geared limit switch section. Press the UP button in the control pendant carefully. Observe the hoisting movement until the operational hoist limit switch switches off in the top hook position (B).
Page 50: Hook Operated Hoist Limit Switch With Switch Rod "Pls" (Option)
Installation 4.12 Hook operated hoist limit switch with switch rod “PLS” (option) The hook operated hoist limit switch is also available as “hook operated hoist limit switch with weight ball” variant. Only one variant can be mounted. (1) C-profile (2) “PLS” switching unit (3) Microswitch (4) Shaft with switching cams (5) Retaining plate...
Page 51: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Stationary Wire Rope Hoists (Yka/Ska / Ykb/Skb)
Installation 4.12.1 Mounting hook operated hoist limit switch with switch rod on stationary wire rope hoists (YKA/SKA / YKB/SKB) Hoist limit switch with attachment set (for reeving 2PS) (1) “PLS” switching unit Hoist limit switch with attachment set (for reeving 4PS) (1) “PLS”...
Page 52 Installation Mounting holes on the lifting beam YKA/SKA (drum length L2) YKA/SKA (drum length L3) YKB/SKB (drum length L2) YKB/SKB (drum length L3) YKB/SKB (drum length L4) Mounting holes for reeving 2PS Mounting holes for reeving 4PS 07.2020...
Page 53 Installation Type Reeving Assembly position YKA/SKA YKB/SKB Observe the mounting positions of the screws (2), see figure above. Fasten the “PLS” (1) switching unit on at the prescribed position with the bolted connections, see figures above. Tighten the bolted connections with the prescribed tightening torque (12 Nm). Perform a functional test, see the Performing a functional test section.
Page 54: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Stationary Wire Rope Hoists (Ykc/Skc)
Installation 4.12.2 Mounting hook operated hoist limit switch with switch rod on stationary wire rope hoists (YKC/SKC) Hoist limit switch with attachment set (reeving 2PS) “PLS” switching unit Hoist limit switch with attachment set (reeving 4PS) “PLS” switching unit Assembly position 1 Assembly position 2 07.2020...
Page 55 Installation Mounting holes on the lifting beam Drum length L2 Drum length L3 Drum length L4 (3) Mounting holes Reeving Assembly position Fasten the “PLS” (1) switching unit on at the prescribed position with the bolted connections, see figures above. Tighten the bolted connections with the prescribed tightening torque (12 Nm).
Page 56: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Stationary Wire Rope Hoists (Yke/Ske / Ykd/Skd)
Installation 4.12.3 Mounting hook operated hoist limit switch with switch rod on stationary wire rope hoists (YKE/SKE / YKD/SKD) (1) “PLS” switching unit Assembly position 1 Assembly position 2 Assembly position 3 dimension [in] 7.05 11.81 07.2020...
Page 57 Installation Arrangement of the mounting positions Type Reeving Drum length Assembly position L2 + L3 + L4 + L5 YKE/SKE L2 + L3 + L4 + L5 YKD/SKD L3 + L4 + L5 L2 + L3 + L4 + L5 Observe the mounting position of the screws (2).
Page 58: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Trolleys (Ke-S
Installation 4.12.4 Mounting hook operated hoist limit switch with switch rod on trolleys (KE-S..) The hook operated hoist limit switch is shipped in transport position, i.e. turned upwards. Before commissioning, the switching unit “PLS” (3) must be turned downwards. Loosen the bracket clips (2). Turn the switching unit “PLS”...
Page 59 Installation Assembly position of the “PLS” switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 (1) Screw (6) Nut (2) Threaded plate (7) C-profile (3) Screw (8) Threaded plate (4) Bracket clip (9) Plate (5) Retaining plate (10) Spacer sleeve 07.2020...
Page 60 Installation Dimension “c” Measured from the centre of the bracket clip upwards. − Measured from the centre of the bracket clip downwards. Arrangement of the mounting positions (KE-S33) Flange width Reeving Assembly position [in] 3.2 – 8.4 8.4 – 31.5 3.2 –...
Page 61 Installation Dimensions “a”, “b”, “c” assignment Flange width Reeving [in] [in] [in] [in] 6.22 4.61 +2.24 6.22 4.61 +2.24 6.22 2.24 -0.08 11.8 4.76 0.47 -6.5 15.7 9.57 0.63 -11.1 19.7 4.84 0.63 -15.83 31.5 2.48 0.63 6.22 4.76 +2.4 6.22 4.76 +2.4...
Page 62 Installation Dimensions “a”, “b”, “c” assignment Flange width Reeving Drum length Remark [in] [in] [in] [in] L2 + L3 6.38 4.76 +2.36 L2 + L3 6.38 4.76 +2.36 L2 + L3 6.38 4.76 +2.36 11.8 L2 + L3 6.97 0.67 -3.9 15.7 L2 + L3...
Page 63 Installation Dimensions “a”, “b”, “c” assignment Flange width Type Reeving Drum length [in] [in] [in] [in] L2 + L3 7.72 3.94 +2.56 L2 + L3 7.72 4.72 +3.35 11.8 L2 + L3 6.54 2.56 15.7 L2 + L3 5.79 0.87 -4.69 19.7 L2 + L3...
Page 64 Installation Arrangement of the mounting positions (KE-S76) Flange width Assembly Type Reeving Drum length position [in] 4.9 – 21.3 L2 + L3 + L4 YKE/SKE 21.3 – 31.5 L2 + L3 + L4 4.9 – 13 13 – 31.5 YKD/SKD 4.9 –...
Page 65 Installation Adjusting hook operated hoist limit switch with switch rod (KE-S..) (1) “PLS” switching unit (2) Microswitch (3) Screw (4) C-profile (5) Screw Adjust the geared limit switch, see Adjusting the geared limit switch section. Press the UP button in the control pendant carefully. Observe the hoisting movement until the operational hoist limit switch switches off in the top hook position (B).
Page 66 Installation Shorten the C-profile (4) in the event of overhangs > 0.39 in. Mark the assembly position of the “PLS” switching unit (1) and the overhang "f" from the C-profile (4). Disassemble the "PLS" switching unit (1) and secure it against falling down. Disassemble the C-profile (4) and shorten it accordingly.
Page 67: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Trolleys (Ue-S77)
Installation 4.12.5 Mounting hook operated hoist limit switch with switch rod on trolleys (UE-S77) Fasten the “PLS” (1) switching unit on at the prescribed position with the bolted connections, see figures above. Tighten the bolted connections with the prescribed tightening torque (12 Nm). Perform a functional test, see the Performing a functional test section 07.2020...
Page 68: Mounting Hook Operated Hoist Limit Switch With Switch Rod On Trolleys (Oe-S)
Installation 4.12.6 Mounting hook operated hoist limit switch with switch rod on trolleys (OE-S) (1) “PLS” switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 07.2020...
Page 69 Installation Assembly position 5 Dimension [in] 3.58 4.84 The arrow in the figure shows the contact area. Assembly Type Trolley type Reeving Drum length position YKA/SKA OE-S04 2PS, 4PS L2 + L3 YKB/SKB OE-S04 2PS, 4PS L2 + L3 + L4 OE-S05 YKC/SKC 2PS, 4PS...
Page 70: Reeving Rope
Installation 4.13 Reeving rope The wire rope is wound onto the drum in the factory. If not, see section Changing the wire rope. The wire rope hoist must be switched on in order to reeve the rope. All work must therefore be carried out with extreme care: for your safety and for smooth functioning of the wire rope hoist! If the bottom hook block is not fitted, proceed as follows:...
Page 71: Overview Of Reeving
Installation 4.13.1 Overview of reeving YKA/SKA YKB/SKB YKE/SKE YKC/SKC Tab. 13 YKA/SKA YKB/SKB YKE/SKE YKC/SKC Tab. 14 YKA/SKA YKB/SKB YKE/SKE YKC/SKC Tab. 15 Fig. 43 Left-handed thread Right-handed thread 07.2020...
Page 72: Rope Fastening Point (Yka/Ska - Yke/Ske)
Installation 4.13.2 Rope fastening point (YKA/SKA - YKE/SKE) If special ropes are used, refer to the section Rope fastening point (YKA/SKA - YKE/SKE) with special ropes. WARNING Danger of falling load If ropes are not secured according to instructions, this leads to the rope slipping and the load falling.
Page 73 Installation Rope fastening point (YKA/SKA - YKE/SKE) with special ropes Procedure only for ropes listed in the table Rope Ø Part number [in] 0.354 A70009035 0.492 A70009036 see works certificate. Rope bag Rope wedge Rope clamp Cotter pin Rope Fig. 45 Clean the rope (5) in the area of the rope anchorage.
Page 74 Installation Load the wire rope hoist multiple times (max. load). The following is recommended: – Load and hold 5 times; each holding phase should last at least one minute. – The result of the load is a rope that is firmly drawn into the rope bag. Check the protruding end of the rope wedge.
Page 75: Position Of The Rope Fastening Point
Installation 4.13.3 Position of the rope fastening point Fig. 46 Wire rope hoist type YKA/ YKB/ YKC/ Tab. 17 Fig. 47 Fig. 48 Fig. 49 Z = on the gear side 07.2020...
Page 76 Installation Wire rope hoist type YKA/ YKB/ YKC/ Fig. 50 Tab. 18 Fig. 51 Z = on the gear side 07.2020...
Page 77 Installation Wire rope hoist type YKA/ YKB/ YKC/ Fig. 52 Type [in] [in] YKA/SKA YKB/SKB 10.4 11.4 YKC/SKC 13.1 14.4 Tab. 19 Fig. 53 Fig. 54 Fig. 55 Z = on the gear side 07.2020...
Page 78 Installation Rope fastening point (YKA/SKA - YKC/SKC) Type [in] [in] YKA/ YKB/ 10.4 11.4 YKC/ 13.1 14.4 Wire rope hoist type YKA/ YKB/ YKC/ Fig. 56 Tab. 20 Fig. 57 Fig. 58 Fig. 59 Z = on the gear side 07.2020...
Page 79 Installation Rope fastening point (YKE/SKE) Wire rope hoist type YKE/SKE Fig. 60 L2 – L5 L2 – L5 L2 – L5 L3 – L5 Tab. 21 Fig. 61 Wire rope hoist type YKE/SKE L2 – L5 L2 – L5 L2 – L5 Tab.
Page 80: Commissioning
Commissioning Commissioning WARNING Danger of personal injuries ➢ Make sure that a competent person authorized to test cranes carries out the commissioning. When commissioning the hoist and after service works, perform repeat testing. The following activities, settings and checks must be carried out: Correct completion of the wire rope hoist with the original accessory parts supplied (e.g.
Page 81: Operating
Operating Operating WARNING Safety hazard. Bridging limit switches or operating the hoist with a damaged rope or brake is not permissible. Operating precautions 1. DO read the Operation & Service Manual. 2. DO read the applicable sections of FEM 9.756, Section IX “SERIES LIFTING EQUIPMENT”...
Page 82 Operating 35. DO NOT allow the rope or hook to be used as a ground for welding. 36. DO NOT allow the rope or hook to be touched by a live welding electrode. 37. DO NOT remove or obscure the warnings on the hoist. 38.
Page 83: Duties Of Crane Operator
Operating Duties of crane operator Personal protective equipment must be provided by the owner. Requirements for workplace 1. The operator must not stand in the hazard area. 2. The hazard area must be clearly visible. 3. The movement of the load in all directions must be clearly visible. WARNING Safety hazard.
Page 84: Control Pendant
Operating Control pendant WARNING Danger of unintentional movement of hoist If the rocker switch is no longer depressed by the operator, it returns to the 0 position, the hoist motion is automatically stopped (dead man’s control). If the hoist malfunctions, e.g. the actual motion does not correspond to the motion intended in activating the rocker switch, release the rocker switch immediately.
Page 85: Hoists With Frequency Converter
Operating Hoists with frequency converter The 2-stage actuation of the pushbuttons enables a fast changeover from "fast" to "slow" and vice versa. Pushbutton is not actuated → Motor does not rotate Stage I on the pushbutton is actuated → Motor accelerates to preset low speed Stage II on the pushbutton is actuated →...
Page 86: Inspection And Maintenance
Inspection and maintenance Inspection and maintenance • This wire rope hoist is largely maintenance-free. • Components that are subject to wear (e.g. wire rope, brake) must be subjected to regular tests. – This is also required by the accident prevention regulations. •...
Page 87: Inspection Intervals
Inspection and maintenance Inspection intervals W0789 W0791 Fig. 66 Inspection table see page ● ● Function of brakes (1) with regard to braking efficiency and activation Functional test of the hoist limit switch: 48, 110, 111 • Operational hoist limit switch, if available. ●...
Page 88: Maintenance Intervals
Inspection and maintenance Maintenance intervals W0792 W0794 W0793 Fig. 67 Maintenance table see page ● Brake (20), measure air gap, replace brake disk if necessary 95, 98, 100, ● Overload safety device (21) ● Grease rope (22) with brush ● Grease rope guide (23) with brush ●...
Page 89: Motors
Inspection and maintenance Motors DANGER Electric shock hazard. Some motor parts are live. Any contact with live parts can cause severe injury or death. Motors have dangerous rotating parts and hot surfaces. Ensure that: • the motor runs correctly (e.g. no variations in speed, no noise emission), •...
Page 90: Changing The Gear Oil
Inspection and maintenance 7.4.1 Changing the gear oil The oil should be drained when at operating temperature if possible. Open the oil drain screw (2) and oil filler plug / bleeder screw (1). Collect oil in a suitable container. Replace copper sealing rings. Tighten the oil drain screw (2) (for tightening torque see table).
Page 91: Drive-Through Mechanism Conversion Or Replacement (Single Girder Trolleys)
Inspection and maintenance Drive-through mechanism conversion or replacement (single girder trolleys) 7.5.1 Drive-through mechanism for travel drive (trolleys KE-S33 - KE-S65) Fig. 68 Depending on the flange width (B) of the runway beam and the length (L) of the drive- through mechanism (1), install the drive-through mechanism in the installation position X3 or X4.
Page 92: Drive-Through Mechanism For Travel Drive (Trolley Ke-S76)
Inspection and maintenance 7.5.3 Drive-through mechanism for travel drive (trolley KE-S76) The drive-through mechanism is suitable for beam flange widths “B” of 4.9…19.7 in; for length “L” see Tab. 24, page 91. Dimension min. max. [in] 0.08 0.16 Drive pinion Spacer tube Adjusting ring Trolley side cheek...
Page 93: Drive-Through Mechanism For Travel Drive (Ue-S776)
Inspection and maintenance 7.5.4 Drive-through mechanism for travel drive (UE-S776) The drive-through mechanism is suitable for beam flange widths “B” of 7.3…19.7 in; for length “L” see Tab. 25. Drive-through shaft Drive pinion Spacer tube Adjusting ring Fig. 70 Guide the drive-through shaft (5) into both drive pinions (1) from the counterweight side.
Page 94: Drive-Through Mechanism For Travel Drive (Dke-S4 / Dke-S6)
Inspection and maintenance 7.5.6 Drive-through mechanism for travel drive (DKE-S4 / DKE-S6) • Drive-through mechanism (1) is suitable for beam widths “B” of 3.5…11.8 in. For length “L”, see Tab. 26. Fig. 71 Trolleys with one travel drive • Assemble retaining rings (1) per dimension L4. •...
Page 95: Hoist Motor Brake (Rsm)
Inspection and maintenance Hoist motor brake (RSM) This inspection and maintenance is of particularly important to ensure safety. If brake maintenance is not performed correctly or the brake does not function correctly, the load may fall! WARNING Danger of falling load Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down.
Page 96: Replacing The Brake Rotor
Inspection and maintenance 7.6.2 Replacing the brake rotor CAUTION Brake dust is hazardous to health. ➢ Do not clean brakes with compressed air, brushes or similar. ➢ Use a vacuum system or a damp cloth to remove brake dust. ➢ If dust develops, wear safety eyewear and a fine dusk mask. WARNING With an incorrectly assembled brake rotor, the brake cannot hold the load and the load will fall.
Page 97 Inspection and maintenance Assemble in reverse order. – Steps 7 to 12 are omitted. – Make sure that the inspection bore for the air gap measurement is in the lower area. – After tightening the fastening screws (8) (for tightening torque see table), mark the fastening screws (8).
Page 98: Hoist Motor Brake (Nm) 12/2H
Inspection and maintenance Hoist motor brake (NM) 12/2H…-MF WARNING Danger of falling load Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Switch off the main isolation switch and secure against being switched on again! Fan cover Stopping plug Fanwheel...
Page 99 Inspection and maintenance Disassemble electrical connection of the brake. Unscrew the fastening screws (4) Remove coil carrier (5) complete with anchor plate (6). Take off brake rotor (7). NOTICE When dampening the cloths, only use isopropyl alcohol. The use of brake cleaner is not permissible.
Page 100: Hoist Motor Brake (Nm) 4H
Inspection and maintenance Hoist motor brake (NM) 4H..-MF WARNING Danger of falling load Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Switch off the main isolation switch and secure against being switched on again! Stopping plug Stopping plug Enclosure upper part...
Page 101: Replacing The Brake Rotor
Inspection and maintenance 7.8.2 Replacing the brake rotor CAUTION Brake dust is hazardous to health. ➢ Do not clean brakes with compressed air, brushes or similar. ➢ Use a vacuum system or a damp cloth to remove brake dust. ➢ If dust develops, wear safety eyewear and a fine dusk mask. WARNING With an incorrectly assembled brake rotor, the brake cannot hold the load and the load will fall.
Page 102 Inspection and maintenance Slide a new brake rotor (11), identical to the previous rotor, onto the hub (12) and check the clearance. NOTICE Danger of damage – If increased clearance is present in the gearing between the brake rotor (11) and hub (12), remove the hub (12) from the motor shaft and replace it.
Page 103: Hoist Motor Brake (Nm) 4Hs
Inspection and maintenance Hoist motor brake (NM) 4HS. WARNING Danger of falling load Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Switch off the main isolation switch and secure against being switched on again! Stopping plug Stopping plug Stud bolt...
Page 104: Replacing The Brake Rotor
Inspection and maintenance 7.9.2 Replacing the brake rotor CAUTION Brake dust is hazardous to health. ➢ Do not clean brakes with compressed air, brushes or similar. ➢ Use a vacuum system or a damp cloth to remove brake dust. ➢ If dust develops, wear safety eyewear and a fine dusk mask. WARNING With an incorrectly assembled brake rotor, the brake cannot hold the load and the load will fall.
Page 105 Inspection and maintenance Slide a new brake rotor (11), identical to the previous rotor, onto the hub (12) and check the clearance. NOTICE Danger of damage – If increased clearance is present in the gearing between the brake rotor (11) and hub (12), remove the hub (12) from the motor shaft and replace it.
Page 106: Replacing The Pressure Springs
Inspection and maintenance 7.10 Replacing the pressure springs CAUTION Brake dust is hazardous to health. ➢ Do not clean brakes with compressed air, brushes or similar. ➢ Use a vacuum system or a damp cloth to remove brake dust. ➢ If dust develops, wear safety eyewear and a fine dusk mask. Fastening screws Coil carrier Pressure spring...
Page 107: Travel Motor Brake
Inspection and maintenance Remove all old pressure screws (3) from the coil carrier (2). Clean the coil carrier (2) with a damp cloth. The thickness and number of windings of the pressure screws may vary. It is therefore essential to symmetrically distribute the pressure springs in the coil carrier. Equip the coil carrier (2) with the correct new pressure spring set.
Page 108: Geared Limit Switch
Inspection and maintenance 7.12 Geared limit switch WARNING Danger of personal injuries ➢ The geared limit switch is built in accordance with state of the art engineering and is operationally safe. ➢ However, it may pose dangers if it is not used as intended. ➢...
Page 109: System Description For Geared Limit Switch - Version 2
Inspection and maintenance 7.12.2 System description for geared limit switch - version 2 This geared limit switch is suitable for wire rope hoists with frequency-controlled hoist motors. The geared limit switch has an emergency hoist limit switch (switching points A and A) for the highest and lowest hook position.
Page 110: Checking The Geared Limit Switch
Inspection and maintenance 7.13 Checking the geared limit switch WARNING Danger due to falling load! ➢ Perform all checks and settings without load only. ➢ Cordon off and secure the danger zone. 7.13.1 Checking the operational hoist limit switch - version 1 (S3) Dim.
Page 111: Checking The Emergency Hoist Limit Switch - Version 1 (S1)
Inspection and maintenance 7.13.2 Checking the emergency hoist limit switch - version 1 (S1) Dim. [in] 50 Hz 60 Hz b = a Effective hook path With the option hook operated hoist limit switch (see section 4.12), dimension “a” increases by 3.9 in, dimension “c”...
Page 112 Inspection and maintenance Carefully actuate the DOWN-button in the control pendant until the emergency hoist limit switch switches off (A). – Do not undershoot the minimum distance “f”, of f ≥ 0.79 in between the rope guide ring (1) and the clamping claws (2) for the rope anchorage. –...
Page 113: Checking The Operational Hoist Limit Switch - Version 2 (S3)
Inspection and maintenance 7.13.3 Checking the operational hoist limit switch - version 2 (S3) Dim. [in] 50 Hz 60 Hz Reeving b = V × t × 0.023 ft V = Hoist speed [fpm] t = Brake ramp [s] (Factory setting = 1.5 s Example: YKC/SKC-L05-…S264-V b = 64 ×...
Page 114: Checking The Emergency Hoist Limit Switch - Version 2 (S1)
Inspection and maintenance 7.13.4 Checking the emergency hoist limit switch - version 2 (S1) Dim. [in] 50 Hz 60 Hz Reeving b = V × t × 0.023 ft V = Hoist speed [fpm] t = Brake ramp [s] (Factory setting = 1.5 s Example: YKC/SKC-L05-…S264-V b = 64 ×...
Page 115 Inspection and maintenance With deviations, adjust the geared limit switch again (see section 7.14 Adjusting the switching points). Actuate the override button (S261) in the control box and the DOWN-button at the same time to exit the top switching area. Actuate the DOWN-button in the control pendant with caution.
Page 116: Adjusting The Geared Limit Switch
Inspection and maintenance 7.14 Adjusting the geared limit switch • With rope drums carrying ropes, the switching points are preset in the factory. • If ropes are delivered loose, the switching points must be set. WARNING Danger due to electrical voltage. The hood must be removed from the geared limit switch to adjust the switching points.
Page 117: Geared Limit Switch - Version 1
Inspection and maintenance 7.14.1 Geared limit switch - version 1 The individual switching points are set in the factory with the adjustment screws “S1” to “S4”. Turning clockwise: Switching point is shifted upwards  Turning anticlockwise: Switching point is shifted downwards  The switching points must be set in the following order: Adjustment Switching...
Page 118 Inspection and maintenance Preparatory work Remove the screws on the hood of the geared limit switch. Remove the hood. NOTICE The geared limit switch can be damaged if an electric screwdriver is used to set the switching points. Adjustment tool for geared limit switch ➢...
Page 119 Inspection and maintenance Adjusting emergency hoist limit switching, “top” (A) The “top” operational hoist limit switching position must be set. Actuate the UP-button in the control pendant with caution. Observe the hoisting movement, until operational hoist limit switching (B) switches off in the top hook position.
Page 120 Inspection and maintenance Dim. [in] 50 Hz 60 Hz b = a Effective hook path With the option hook operated hoist limit switch (see section 4.12), dimension “a” increases by 3.9 in, dimension “c” increases in accordance with the table. Type Dimension “c”...
Page 121: Geared Limit Switch - Version 2
Inspection and maintenance Lower the load hook to 0.39 in in front of the switching point (A). – Do not undershoot the minimum distance “f”, of f ≥ 0.79 in between the rope guide ring (1) and the clamping claws (2) for the rope anchorage. –...
Page 122 Inspection and maintenance Preparatory work Remove the screws on the hood of the geared limit switch. Remove the hood. NOTICE The geared limit switch can be damaged if an electric screwdriver is used to set the switching points. Adjustment tool for geared limit switch ➢...
Page 123 Inspection and maintenance Adjusting operational hoist limit switching, “bottom” (B) Actuate the DOWN-button in the control pendant with caution. Lower the load hook to 0.39 in in front of the switching point (observe the minimum distance “d”). – If the operational hoist limit switch should switch off beforehand, turn the adjustment screw “S6”...
Page 124: Hook Dimensions C For Ke-S
Inspection and maintenance Actuate the override button (S262) in the control box and the DOWN button at the same time, until 0.39 in before the switching point (A). – Do not undershoot the minimum distance “f”, of f ≥ 0.79 in between the rope guide ring (1) and the clamping claws (2) for the rope anchorage.
Page 125 Inspection and maintenance “B” Flange width “C” Hook dimension “C” YKA/SKA 2PS L2-L3 YKA/SKA 2PS L2-L3 PLS YKA/SKA 2PS L2-L3 BLS Flange width [in] Instructions for using the diagram Select the diagram line for the wire rope hoist. Draw a vertical line for the corresponding flange width. Draw a horizontal line though the point of intersection and read off the hook dimension “C”.
Page 126 Inspection and maintenance YKA/SKA 4PS L2-L3 YKA/SKA 4PS L2-L3 PLS YKA/SKA 4PS L2-L3 BLS YKA/SKA 2PD L2-L3 YKA/SKA 2PD L2-L3 BLS Flange width [in] YKB/SKB 2PS L2-L3 YKB/SKB 2PS L2-L3 PLS YKB/SKB 2PS L2-L3 BLS YKB/SKB 2PS L4 YKB/SKB 2PS L4 PLS YKB/SKB 2PS L4 BLS Flange width [in] 07.2020...
Page 127 Inspection and maintenance YKB/SKB 4PS L2-L4 YKB/SKB 4PS L2-L4 PLS YKB/SKB 4PS L2-L4 BLS YKB/SKB 2PD L2-L3 YKB/SKB 2PD L2-L3 BLS Flange width [in] YKC/SKC ≤2500daN 2PS L2-L3 YKC/SKC ≤2500daN 2PS L2-L3 PLS YKC/SKC ≤2500daN 2PS L2-L3 BLS YKC/SKC ≤2500daN 2PS L4 YKC/SKC ≤2500daN 2PS L4 PLS YKC/SKC ≤2500daN 2PS L4 BLS Flange width [in]...
Page 128 Inspection and maintenance YKC/SKC ≤2500daN 4PS L2-L4 YKC/SKC ≤2500daN 4PS L2-L4 PLS YKC/SKC ≤2500daN 4PS L2-L4 BLS YKC/SKC ≤2500daN 2PD L2-L4 YKC/SKC ≤2500daN 2PD L2-L4 BLS Flange width [in] YKC/SKC >2500daN 2PS L2-L3 YKC/SKC >2500daN 2PS L2-L3 PLS YKC/SKC >2500daN 2PS L2-L3 BLS Flange width [in] 07.2020...
Page 129 Inspection and maintenance YKC/SKC >2500daN 4PS L2-L3 YKC/SKC >2500daN 4PS L2-L3 PLS YKC/SKC >2500daN 4PS L2-L3 BLS YKC/SKC >2500daN 2PD L2-L3 YKC/SKC >2500daN 2PD L2-L3 BLS Flange width [in] YKD/SKD 2PS L2 YKD/SKD 2PS L2 PLS YKD/SKD 2PS L2 BLS YKD/SKD 2PS L3-L4 YKD/SKD 2PS L3-L4 PLS YKD/SKD 2PS L3-L4 BLS...
Page 130 Inspection and maintenance YKD/SKD 4PS L2-L4 YKD/SKD 4PS L2-L4 PLS YKD/SKD 4PS L2-L4 BLS Flange width [in] YKE/SKE 2PS L2-L4 YKE/SKE 2PS L2-L4 PLS YKE/SKE 2PS L2-L4 BLS YKE/SKE 2PD L2-L4 YKE/SKE 2PD L2-L4 BLS Flange width [in] 07.2020...
Page 131: Assembling The Bottom Hook Block
Inspection and maintenance 7.16 Assembling the bottom hook block WARNING Danger due to falling load! An incorrectly assembled bottom hook block can lead to serious accidents. ➢ Check the bottom hook block daily for damage and correct seating. Type [in] YKA/SKA YKB/SKB 0.98...
Page 132: Overload Safety Device
Inspection and maintenance 7.17 Overload safety device 7.17.1 Testing overload safety device If an overload is detected, the wire rope hoist is switched off in the upwards direction. Only lowering is then possible. Lifting is not possible until the wire rope hoist has been unloaded.
Page 133: Rope Drive
Inspection and maintenance 7.19 Rope drive 7.19.1 Rope and rope attachment - general information WARNING Danger due to damaged or twisted ropes! A twist in the rope impairs its safety and durability. ➢ Therefore always remove twists! WARNING Danger due to wire breakage! With specific applications (e.g.
Page 134: Replacement Of Wire Rope Due To Broken Wires
Inspection and maintenance 7.19.2 Replacement of wire rope due to broken wires The part number of the rope is listed in the works certificate. Wire ropes must be replaced if one of the following criteria applies. The listed criteria are examples derived from the standard ISO 4309 2017-11 Cranes - Wire ropes - Care and maintenance, inspection and discard.
Page 135 Inspection and maintenance Loop formations ➢ Replace wire ropes with loop formations. Local increase of the rope diameter ➢ Replace wire ropes with the following local rope diameter increases. ≤ 5 % with wire ropes with steel core ≤ 10 % with wire ropes with fibre core Flattening ➢...
Page 136: Removing The Rope Guide
Inspection and maintenance 7.19.3 Removing the rope guide NOTICE Danger of material damage The stop with bearing (2) is secured with a spring washer DIN 6796. This protection must be correctly reinstalled. YKA/SKA - YKC/SKC YKE/SKE Fig. 79 Fig. 80 Unscrew the protective plate (1) beneath the rope drum at the points (a).
Page 137: Installing The Rope Guide
Inspection and maintenance 7.19.4 Installing the rope guide Place the ring half of the rope guide with small opening (1) next to the last rope winding of the rope drum such that the wire rope exits the opening “X”. Special tool, Part no.
Page 138 Inspection and maintenance If necessary, assemble the stop (6) with bearing and spring washer (for tightening torques see table). Type Thread size Tightening torque YKA/SKA−YKB/SKB M8×1 YKC/SKC M10×1 YKE/SKE M16×1 Install the grease pan again! Observe the minimum distance f (≥ 0.79 in) between the rope guide ring (1) and clamping plates (2) for the rope anchorage.
Page 139: Replacing The Rope Guide
Inspection and maintenance Assemble the protective plate (8). Tighten the clamping plates (9) with screws (10) and safety washers (for tightening torques see table). Type Thread size Tightening torque YKA/SKA YKB/SKB YKC/SKC YKE/SKE 7.19.5 Replacing the rope guide The rope guide ring has 2 pre-drilled holes 10° and 30°. Rope guide rings for other angles must be drilled according to the order.
Page 140: Changing The Wire Rope
Inspection and maintenance 7.19.6 Changing the wire rope WARNING Danger due to unsuitable rope The replacement rope must be the same as the original rope. To determine which wire rope is installed, refer to the works certificate or rope certificate. WARNING Always tighten and secure ropes at the rope fastening point according to instructions.
Page 141 Inspection and maintenance Fitting the wire rope WARNING Danger of personal injuries. ➢ After applying a new rope or shortening the old rope, it is necessary to adjust the hoist limit switch. Fig. 82 Roll out the new wire rope straight on a clean and level surface. When unrolling, make sure no loops, bends or twists arise and that no foreign objects penetrate the wire rope.
Page 142 Inspection and maintenance With the block adjustment, set the switch-off at the top (see section 7.14 Adjusting the switching points). – Turning clockwise: Switching point is shifted upwards . Reeve the loose rope end through the hook block according to the number of strands, mount and fasten with the rope wedge and secure with a rope clamp (see section 4.13.2 "Rope fastening point").
Page 143: Checking Rope Drum For Wear
Inspection and maintenance 7.19.7 Checking rope drum for wear Fig. 84 Type of wire Rope diameter Nominal values Limits for wear rope hoist da min di min t max [in] [in] [in] [in] [in] [in] [in] YKA/SKE 0.217 4.91 4.73 0.087 4.88 4.71...
Page 144: Checking And Maintaining The Rope Sheave
Inspection and maintenance 7.19.8 Checking and maintaining the rope sheave Relieve rope tension. Check rope sheaves for wear. We recommend a test by our competent personnel. It is also necessary to ensure smooth running, which indicates that the ball bearing is in good condition.
Page 145 Inspection and maintenance The rope sheave must be replaced if the wall thickness as measured is <t min or the groove depth as measured is > h max. Furthermore, the rope sheave must be replaced when replacing the wire rope if the rope strands have dug into the base of the groove. Impressions of single wires are acceptable.
Page 146: Checking The Load Hook
Inspection and maintenance 7.19.9 Checking the load hook NOTICE Danger of material damage The bottom hook block must be checked for damage. Deformations, cracks and cuts caused by impact must be assessed. The damage can only be assessed by a qualified person. Warning A damaged load hook can cause the load to fall and result in serious injuries.
Page 147: Trolley
Inspection and maintenance 7.20 Trolley Wheels, wheel drive and runway Fig. Nominal value Limit for wear Ø d Ø d1 [in] 3.15 1.08 2.99 1.16 3.94 3.74 1.38 1.75 1.85 5.51 5.24 1.67 1.77 1.75 5.98 1.85 7.87 1.67 7.48 1.77 Tab.
Page 148: Remaining Service Life
Inspection and maintenance 7.21 Remaining service life The operating mode and operating time must be established by the owner, see section 1.3 and recorded in the logbook in order to calculate the remaining service life. After the service life has expired a general overhaul (S.W.P. = Safe Working Period) must be carried out.
Page 149: General Overhaul
Inspection and maintenance 7.22 General overhaul The mechanism (motor and gear; not applicable to wearing parts) of the YK/SK wire rope hoist is classified according to ISO. The theoretical full load lifetime in hours shown opposite (D) is applicable for normal hoist applications. If the full load lifetime (D) minus the lifetime expired is nought, the wire rope hoist must be overhauled by the manufacturer.
Page 150: Wearing Parts
Wearing parts Wearing parts WARNING Safety hazard. ➢ Make sure that replacement and repairs are performed by qualified persons only. Serial number When ordering original spare parts, always indicate the serial number of the hoist. This is affixed to the inside of the bearing support plate. Fig.
Page 151 Wearing parts Rope guide Wire rope hoist type Order no. Order no. Order no. YKA/SKA A0343002430 A0343001430 A0343000430 YKB/SKB A0443000430 A0443002430 A0443001430 YKC/SKC A0543001430 A0543002430 A0543000430 YKE/SKE (2PS), L4 - L5 A0643008430 YKE/SKE A0643003430 A0643004430 A0643000430 Tab. 41 Fig. 94 Wire rope (E) See factory certificate or rope certificate for length and number of wire rope.
Page 152: Troubleshooting
Troubleshooting Troubleshooting DANGER Electric shock hazard. ➢ Make sure an electrical qualified person performs the work. ➢ Disconnect power and implement a Lockout/Tagout (LOTO) procedure before servicing the equipment. Trouble Possible cause Remedy Hoist does NOT operate No power to hoist 1.
Page 153 Troubleshooting Trouble Possible cause Remedy Loud clicking noise when motor Air gap on brake is too wide 1. Measure air gap on motor. starts 2. Replace brake disk if the maximum air gap is reached. Lifting of rated load NOT Low voltage 1.
Page 154: Decommissioning
Decommissioning Decommissioning 10.1 Dismantling WARNING Falling parts hazard ➢ Secure hoist when dismantling. 1. Dismantle hoist correctly. 2. First remove lubricants. 10.2 Scrap disposal NOTICE Electronic components, electric scrap, lubricants and other auxiliary substances are hazardous waste and may only be disposed of by approved recycling companies. Overload devices must be returned to the manufacturer.
Page 155: Technical Data
Technical data Technical data 11.1 Conditions of use The hoist is designed for use in industry and for the ambient conditions usual in industry in non-hazardous areas. Special measures are necessary for particular applications such as e.g. high degree of chemical pollution, outdoor use, offshore application, etc.
Page 156: Hoist
Technical data 11.2 Hoist The designation of the type of wire rope hoist and the motor installed can be seen from the rating plate/factory certificate. All technical data given refer to the standard version and standard operating conditions. The technical data given in the order acknowledgement or individual documentation apply for optional versions and off-standard applications.
Page 157: Pole-Changing Hoist Motors 12/2H
Technical data 11.2.2 Pole-changing hoist motors 12/2H..-MF 60Hz 60 Hz Nominal Starting Nominal Starting Main fuse CC / J Duration Switching/ current current current current Power factor hour Motor cos phi k 208…230 V 360…400 V 208…230 V 360…400 V [HP] CDF [%] [c/h]...
Page 158: Pole-Changing Hoist Motors ../.H.. 50Hz
Technical data 11.2.3 Pole-changing hoist motors ../.H.. 50Hz 50 Hz Nominal Starting Nominal Starting Main fuse CC / J Duration Switching/ current current current current Power factor hour Motor cos phi k 220…240 V 380…415 V 220…240 V 380…415 V [HP] CDF [%] [c/h]...
Page 159: Frequency-Controlled Hoist Motors 4H
Technical data 11.2.5 Frequency-controlled hoist motors 4H..-MF 100 Hz 100 Hz Nominal current Main fuse CC / J Power Duration factor Hoist motor 380…415 V 500…525 V 660…690 V 380…415 V 500…525 V 660…690 V [HP] CDF [%] 4H33-MF 4H42-MF 10.7 15.5 12.4...
Page 160: Frequency-Controlled Hoist Motors 4Hs.-Mf 100 Hz
Technical data 11.2.7 Frequency-controlled hoist motors 4HS.-MF 100 Hz 100 Hz Nominal current Main fuse CC / J Power Duration factor Hoist motor 380…415 V 500…525 V 380…415 V 500…525 V [HP] CDF [%] 4HS3 10.7 15.5 12.4 4HS5 10.1 18.0 14.4 12.1...
Page 161: Cable Cross Sections And Lengths Of Supply Cable
Technical data 11.3 Cable cross sections and lengths of supply cable 11.3.1 Cable cross sections and lengths of supply cable for pole-changing hoist motors 12/2H..-MF Hoist Stationary Hoist Hoist/crane Hoist Rising mains Crane Crane max. 33 ft motor type Fixed installation in PVC Fixed installation in PVC Festoon cable in free air Fixed...
Page 162: Cable Cross Sections And Lengths Of Supply Cable For Pole-Changing Hoist Motors
Technical data 11.3.2 Cable cross sections and lengths of supply cable for pole-changing hoist motors ../..H.. Hoist Stationary Hoist Hoist/crane Hoist Rising mains Crane Crane max. 33 ft motor type Fixed installation in PVC Fixed installation in PVC Festoon cable in free air Fixed Festoon cable in free air Festoon cable in free air...
Page 163: Tightening Torques
Technical data 11.4 Tightening torques All screws should be tightened with a torque spanner. See Tab. 52 for the tightening torques generally applicable for screws grade 8.8 and 10.9. Values (Y) apply for the attachment of the mounting plate to the gear. WARNING Safety hazard.
Page 164 Technical data Other screw connections and applicable tightening torques Screw connection Screw connection Tightening torque Wire rope type Part 1 / Part 2 Thread size Grade Gear casing/panel box YKA/SKA – YKB/SKB YKA/SKA Gear casing/support plate YKB/SKB YKC/SKC Rope drum/gear drive shaft YKC/SKC Rope drum/clamping plate YKA/SKA...
Page 165: Lubricants
Technical data 11.5 Lubricants YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE, YKA/SKA, YKB/SKB, YKC/SKC, YKD/SKD YKE/SKE F0450a Fig 97 Lubrication point Type of lubricant Factory filling (DIN 51502) Alternative lubricants Quantity Aral Degol BG 460 Plus YKA/SKA: 1.32 qt Castrol Alpha SP 460 YKB/SKB: 1.76 qt Fuchs Renolin CLP 460 Castrol Tribol 1100/460...
Page 166 WARRANTY LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES INDEMNIFICATION AND SAFE OPERATION C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD PARTY WITH RESPECT TO ANY GOOD, WHETHER IN CONTRACT, Buyer shall comply with and require its employees to comply with directions set forth in TORT OR OTHER THEORY OF LAW, FOR LOSS OF PROFITS OR LOSS instructions and manuals furnished by Seller and shall use and require its employees OF USE, OR FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL,...

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Yale HOISTS SHAW-BOX YKA Operation & Service Manual

1 General Information

2 General Safety Notes

3 Introduction

4 Installation

5 Commissioning

6 Operating

7 Inspection and Maintenance

8 Wearing Parts

9 Troubleshooting

10 Decommissioning

11 Technical Data

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